I am going to be pulling my 7.3 engine out of my 2000 Excursion this spring to replace the oil pan. Currently has about 176k miles. It has a 6 position chip and is my daily driver. I have transmission temp, EGT and boost gauges.

What else should I do while the engine is out? These are my thoughts:
-Replace oil pan
-New 4” turbo back exhaust (currently stock)
-Replace cooling fan (blades)
-Basic turbo rebuild Garrett Turbo Rebuild Kit 99-03 7.3L Ford Powerstroke
-WW2 upgrade (any better options at a similar price point?)
-Clean/paint the block/etc
-Power steering gear box: (which is better?)
-AGR Ford Applications - AGR Performance - MB Motorsports
-Redhead Red-Head Steering Gears - Custom Rebuilt Steering Gear Boxes in USA
-Power steering lines
-Front brake lines
-Transmission lines
-Reroute fuel filter drain hose for easier catching of fuel when draining
-Coolant filter http://www.dieselsite.com/1999-2003f...ionsystem.aspx




These are things that have been replaced within the 18 months or so:
-Glow plugs
-Glow plug module
-Fuel filter drain o-rings
-Coolant flush/new coolant (Delo Extended Life Antifreeze/Coolant)
-New coolant reservoir
-New upper/lower radiator hoses
-AC condenser (hit a deer)
-Transmission cooler (hit a deer)
-Intercooler (hit a deer)
-Headlights, grill updated to 2007 style (hit a deer)
-Fuel tank pickup filter
-Brake lines to the rear/brake fluid flush


Items I'm unsure of:
-Replace wastegate actuator (What makes a “good” replacement and what is the benefit over stock?)
-Is there maintenance or basic rebuild kit that is recommended for the HPOP?

 

Not to be funny but one thing you can and I should definitely do is spend a good day scrubbing the engine bay. Hell, depending on how nice your truck is and how much you love it you might even want to remove all the hoses and wires and have it sandblaster and painted! If it were my truck I would, this is the only/best time to have it done. I would even consider rhino lining it! You could do a color match rhino line and it would look insane!

Here's an example:

 

Up-pipes and oil rail plugs on the back of the heads.

 

WOW!!!! That looks NICE! Do you have a picture of it after all the lines and wiring were put back in, with and without the engine?

Looks like you put in new engine mounts as well? Where did you get them, the look sharp?!

 

Oh that's not mine, I just googled Honda before and after engine bay. Back when I was doing Honda and Nissan motor swaps I usually just did Krylon and simple wire tucks when I had the motor out. If I ever did my X and it was a diesel I would go this route though.

 

I would do a fuel rail crossover 7.3L Diesel Fuel Rail Crossover? (FRx) 99-03 Powerstroke
Oil crossover Stainless Steel HPX for Ford 7.3L 99-03
Boot kit and clamps Complete CAC Intercooler Boot Kit - Ford 7.3L Powerstroke 99-03

Braided steel brake lines- I use Russell
If 4x4, braided steel ESOF lines http://www.dieselsite.com/1999-2004f...ofhosekit.aspx

I love my Redhead steering box (got 'em on 2 trucks).

Wastegate control http://www.dieselsite.com/19995-2003...ontroller.aspx
The description says it all- works great.

Stock airboxes can leak and 'dust' your engine- pays to check it or replace it for peace of mind. I have a Afe Power Stage 2 Pro 5R Cold Air Intake System Ford F 250 F 350 7 3L Diesel | eBay

 

contact clay at Riffraff and have a talk with him. telling him what you are doing and what you hope to accomplish and of course your budget. he will steer you in the right direction and he has some of the best prices around.

I would really consider the up pipes. you don't want to tackle that job after you put the engine back. I didn't enjoy doing that one bit, I wish I could have gone your route.

 

No rebuild kit I am aware of.

IF your HPOP ever takes a dump, upgrade to a T500 from Terminator Engineering.

I would look into replacing the fuel lines, upgrading the plenum Riffraff Diesel Billet Intake Manifold Plenums for Ford 7.3L 94-03 or at least adding plenum inserts RDP Plenum Reinforcing Inserts? - Ford 7.3L 99.5-03 and the up pipes as has already been mentioned by Lambert.

I dunno how much money you wanna spend, or just how "preventive" you wanna get with preventive maintenance, but also maybe consider replacing the engine bay harness (long-term heat makes the insulation brittle and vibrations cause bare wires with cause shorts), UVCH on each head, HPOP lines (15 years under all that pressure takes its toll) and upgrading the ground wire from the battery.

Stewart

 

In addition to what Stewart suggested, I'd also look into:

Riffraff CVD fittings and Banjo bolts-I'm installing these on a 2002 F350 for a fellow FTE member. With these, you can support up to 160/100 injectors and not starve them for fuel or need a regulated return, especially if you have the Frx.

John Woods Valve Body- See below

In line magnetic filter- this will catch any metal particles in addition to the pan magnet. I firmly believe this, the shift kit I had installed, and regular fluid flushed is what kept my trans together for over 300K since the rebuild.

Bottom line: Clay has spent a lot of time and money developing his own products that over come the engineering flaws in the 7.3 and make it better than the day it rolled off the assembly line. If you spend the money on the Riffraff parts, you won't regret it. I've installed his products on my 7.3 Excursion and other 7.3s and these trucks are much better with the parts Clay developed.

 

Had to have the oil pan replaced on the 99 F250 last year 330K miles. When out the shop replaced the turbo pedestal, and a few other smaller things.

 

Personally if I had the engine out I would take time to add sound deadener to the firewall. Nearly impossible with engine in. Or if the dash is being removed it could be done from the inside. Depends if you like a quiet ride or not I suppose.